Hustler® Super S™ Operator`s Manual

Hustler® Super S™
Operator’s Manual
200 South Ridge Road
Hesston, Kansas
67062
606278
REV A
WARNING
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER
This equipment may create sparks that can start fires around dry vegetation. California Public Resources Code
Section 4442.6 provides that it is unlawful to use or operate an internal combustion engine on any forest-covered,
brush-covered, or grass-covered land unless the engine is equipped with a spark arrester maintained in effective
working order. A spark arrester is a device constructed of nonflammable materials specifically for the purpose of
removing and retaining carbon and other flammable particles over 0.0232 of an inch in size from the exhaust flow of
an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States
Forest Service. Other states or federal areas may have similar laws. The Operator Should Contact Local Fire
Agencies For Laws or Regulations Relating to Fire Prevention Requirements. THIS EQUIPMENT DOES NOT HAVE
A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF
A SPARK ARRESTER.
Inspect spark arrester daily; replace every 500 hours or as needed.
The Engine Owner’s Manual provides information regarding the U.S. Environmental Protection Agency (EPA)
and the California Emission Control Regulation of emission systems, maintenance and warranty.
Keep Engine Owner’s Manual with your unit. Should the Engine Owner’s Manual become damaged or
illegible, replace immediately. Replacements may be ordered per the information found in the Product
Information section of the owner’s manual.
Federal law and California State law prohibit the following acts or the causing thereof:
1. The removal or rendering inoperative by any person other than for purposes of maintenance,
repair, replacement, of any device or element of design incorporated into any equipment for the
purposes of emissions control prior to or after its sales or delivery to the ultimate purchaser or
while it is in use, or
2. The use of the equipment after such device or element of design has been removed or rendered
inoperative by any person.
REV A
606278
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
To the New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model and Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-1
1-1
1-1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Safety and Instructions Decals. . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Start Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moving the Mower With Stalled Engine . . . . . . . . . . . . . . . . . . .
Mower Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Cutting Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . .
Anti-scalp Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-1
3-1
3-2
3-3
3-3
3-4
3-4
3-8
3-8
Maintenance & Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safe Servicing Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel and Evaporative Emissions Control System . . . . . . . . . . .
Engine Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . .
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
606278
toc-1
4-1
4-1
4-1
4-1
4-1
4-1
4-2
4-2
4-5
4-5
4-7
4-7
REV A
Mower Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Operator Platform Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Product Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
REV A
toc-2
606278
GENERAL INFORMATION
This manual applies to the following Hustler ® Turf Equipment product lines:
rience, operators should develop safe operating practices
suitable to most conditions.
Directions used in this manual, for example RIGHT or LEFT,
refer to directions when in the operator position and facing
forward, unless otherwise stated.
Hustler® Super S™
To the New Owner
Hustler Super S™ mowers are designed to be used for mowing purposes only. Use of this mower for any other purpose
could prove to be dangerous to the operator and/or bystanders.
Hustler® mower owners and operators must read this manual carefully. It contains operation and maintenance information that will help you achieve years of dependable service.
The Engine Owner’s Manual, included in the owner’s
packet, contains engine information that will not be repeated
in this manual.
The owner’s responsibilities include, but are not limited to,
making certain that the operators and mechanics:
• read and understand the engine owner’s manual
before attempting to operate or repair the engine.
• read and understand the mower’s operator manual and
all decals before operating this machine.
• are qualified and physically able individuals, properly
trained in the operation and maintenance of this
equipment. Before they are allowed to operate or
maintain this machine, they must be familiar with its
safe operation, operator controls, and decals.
• know they are responsible for their own safety as well
as the safety of other persons within the vicinity.
Remember, the operator is responsible for accidents
or hazards occurring to other people or their property.
• who cannot read and understand English have this
material explained to them.
IMPORTANT: As the owner/operator you can prevent accidents. You are responsible for accidents or injuries occurring
to yourself, other people or property.
Though current at the time of printing, photographs and
illustrations shown may vary slightly from your mower due to
subsequent production changes. Hustler® Turf Equipment,
Inc. reserves the right to redesign and change the machine
as deemed necessary, without notification. If a change has
been made to your machine which is not reflected in this
manual, contact your Hustler® Dealer for current information.
Warranty Registration
To activate your warranty policy the mower must be registered, by your Dealer, with the Manufacturer of Hustler® Turf
Equipment within ten (10) days following the date of purchase. It is recommended that you contact your Dealer to
make sure the mower is registered.
IMPORTANT: The mower and any attachment that displays a model and serial identification number plate must be
registered with Excel Industries, Inc., manufacturer of Hustler® Turf Equipment, Inc (“Manufacturer”).
IMPORTANT: Any unauthorized modification, alteration,
or use of non-approved attachments voids the warranty and
releases Manufacturer and Hustler® Turf Equipment, Inc.
from any liability arising from subsequent use of this equipment. Do not use or operate any attachment not approved by
Hustler Turf Equipment, Inc.
Model and Serial Number
The serial identification plate, located on the mower frame
directly below the battery compartment, contains the
mower’s model and serial numbers.
These numbers are required when the unit is registered
with Hustler® Turf Equipment. They will also assure you of
the correct service parts when replacement becomes necessary.
Never let children or untrained people operate or service
the equipment. Local regulations may restrict the age of the
operator.
Parts and Service
For more detailed maintenance and adjustment information refer to the proper General Service Manual for your
machine. Refer to the Product Literature section of this manual for information on how to obtain this manual.
Use only original Hustler® replacement parts available from
your local Hustler® Dealer. For prompt, efficient service,
always provide the following information when ordering
parts:
Using this Manual
1.
Correct part description.
2.
Correct part number.
This manual contains general operation information as
well as basic adjustment and maintenance information.
Since operating conditions vary considerably, all conditions
cannot be addressed individually. Through training and expe-
3.
Correct model number.
4.
Correct serial number.
606278
1-1
All arrangements for warranty repair and service must be
handled through an authorized Hustler® Dealer.
REV A
REV A
1-2
606278
SAFETY PRECAUTIONS
Incorrect usage of this equipment may result in severe injury.
Personnel operating and maintaining it should be trained in its
proper use. They should read this manual completely and thoroughly before attempting to set-up, operate, adjust, or service
this equipment.
Safe Operating Practices
DANGER
This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL
SAFETY for operators and other persons during the normal
operation and servicing of this equipment.
– denotes immediate hazards which WILL result in
severe personal injury or death.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
 Never allow persons to operate this mower without
proper instruction or allow children to operate the
mower. Allow only responsible adults who are familiar
with these instructions to operate this mower.
Safe Operation
WARNING
 Evaluate the terrain to determine what accessories
and attachments are needed to properly and safely
perform the job. Only use accessories and attachments approved by the manufacturer.
• Do not use any unauthorized attachment or modify the mower.
– denotes a hazard or unsafe practice which COULD
result in severe personal injury or death.
• Follow the manufacturer’s recommendation for
wheel weights or counterweights.
This manual uses two other words to highlight information:
A.
IMPORTANT – calls attention to special mechanical
information.
B.
NOTE – emphasizes general information worthy of
special attention.
The owner’s responsibilities include, but are not limited to,
• making certain that the operators and mechanics read
and understand this manual and all decals before
operating this machine.
• making certain that before the operators and mechanics are allowed to operate or maintain this machine,
they must be familiar with its safe operation, operator
controls, and decals.
• ensuring that the operators and mechanics know they
are responsible for their own safety as well as the
safety of other persons within the vicinity. Remember,
the operator is responsible for accidents or hazards
occurring to other people or their property.
Improper use, adjustment, or maintenance by the operator,
mechanic or owner can result in injury. Reduce the potential
for injuries by following these safety instructions. Pay close
attention to the safety alert symbol “” and the instructions
that follow it. Failure to comply with these instructions may
result in personal injury or death.
606278
2-1
• Any rapid movement of the steering control
levers in either direction could result in a reaction
of the mower that can cause serious injury especially if an attachment or weights are added.
 Always be alert and inspect area to be mowed for hazards such as rocks, metal objects and other debris
which may be thrown or entangled by mower blades.
Remove these objects before mowing. Watch out for
holes or deep depressions.
 Always operate mower in daylight or with adequate
working lights.
 Never operate the mower when there is a risk for lightning.
Personal Safety
 Always wear long pants and safety shoes with slipresistant soles when operating this mower.
• Do not wear sandals, tennis shoes, sneakers,
shorts or any type of loose fitting clothing as they
may get tangled in moving parts.
• Do not wear a towel from the waist, or use a towel
as a headband or neck wrap.
• Long hair or jewelry may get tangled in moving
parts.
 Always wear adequate ear protection, such as earplugs. Prolonged exposure to loud noise can cause
impairment or loss of hearing.
REV A
engine and be sure the blades have stopped before
cleaning. Use a stick to clear a plugged discharge
area. Never use your hand!
• Do not wear radios or music headphones while
operating this mower. Safe operation requires
your full attention.
 Always wear safety goggles or safety glasses with side
shields when operating this mower.
 Do not operate the mower if you are fatigued, sick or
while under the influence of alcohol or drugs, if you are
pregnant or under 18 years old.
 Poor posture or operating the mower for extended periods of time may lead to fatigue or injury, resulting in
loss of mower control. Occasionally, stop the mower
and get off the mower to stretch and relax.
 This product is designed to be used by physically fit,
professional operators who have significant experience operating commercial mowers.
 Data indicates that operators, age 60 years and above,
are involved in a large percentage of mower-related
injuries. These operators should evaluate their ability
to operate the mower safely enough to protect themselves and others from serious injury.
Operation
 Never leave a running mower unattended. Before leaving the operator’s platform for any reason, including
emptying the catcher or unclogging the chute:
• Always stop on level ground.
 Follow daily and weekly checklists, making sure hoses
are tightly secured and bolts are tightened.
• Never operate a poorly maintained mower.
 Clean flammable material from mower. Prevent fires by
keeping the engine compartment, top of the deck,
exhaust area, battery (if applicable), fuel line, fuel tank
and operator’s station clean of accumulated trash, grass
clippings, and other debris. Always clean up spilled fuel
and oil.
 Allow the mower, especially the engine, to cool before
storing inside a building or trailer.
 Never cover the machine with a tarp or cover of some
type until the engine and muffler have cooled.
 Do not change the engine governor setting or over
speed the engine. Operating the engine at excessive
speed may increase the hazard of personal injury.
 Rapid movement of the steering control levers in either
direction could result in a reaction of the mower that
can cause serious injury.
• Never push forward suddenly on your steering
control levers while the mower is in rearward
motion because mower may tip backwards.
• Never pull back suddenly on your steering control
levers while the mower is in forward motion.
• Disengage the deck clutch.
• Place the steering control levers in the neutral
position.
 Always be aware of what is behind the mower before
backing up. Never mow in reverse. Always look down
and behind before and while backing up.
• Place the park brake lever in the engaged park
brake position.
• If mowing in reverse is unavoidable, rapid movement of the steering control levers in either direction could result in a reaction of the mower that
can cause serious injury.
• Stop the engine.
• Remove the ignition key.
• Wait for the engine and all moving parts to come
to a complete stop.
 Always inspect mower for damage after striking a foreign object. If damage is found, repair mower immediately.
 Only start the engine from the operator’s position.
 Make sure you keep both feet securely on the operator’s platform while using this machine, especially
when backing up.
IMPORTANT: If both feet are not placed securely on the
operator’s platform, slipping could occur.
 Turn off the mower blades when not mowing.
 Keep the operator’s platform clean of debris/mud or
slipping could occur.
 Always keep safety shields and covers in place, except
for servicing.
 Slow down before turning.
 Never operate the mower deck with the discharge
chute damaged, altered, removed, or in the raised position, except when the entire grass catcher attachment
or mulching system is being used.
 Always keep clear of the mower blades and attachments during their operation.
• Never put hands or feet under any part of the
mower while it is running.
 Stop the engine before removing the grass catcher or
unclogging the discharge chute. Never clear the discharge chute with the engine running. Turn off the
REV A
2-2
 Operate a safe distance (minimum of 10 feet) away
from drop-offs, retaining walls, drainage ditches,
embankments, water, and other types of hazards to
avoid a wheel dropping over the edge or to avoid the
ground from breaking away. This will reduce the risk of
the mower suddenly rolling over causing serious injury
or death.
 Use a walk-behind, push mower or hand-held trimmer
on slopes and near drop-offs, retaining walls, drainage
ditches, embankments and water to avoid mower rollover and serious injury or death.
 Do not tow with this mower.
606278
 Close the fuel shut-off valve when transporting or storing the mower.
 Never attempt high speed maneuvering, especially in
crowded or congested areas.
 Always maintain a safe distance from people and pets
when mowing. Always stop mower if someone enters
the area.
 Never carry passengers.
 Never direct discharged material toward anyone. Avoid
discharging material against a wall or obstruction.
Material may ricochet back toward the operator.
Always disengage the mower blades and wait for them
to stop before crossing gravel drives, walks or roads.
 Always observe traffic laws while driving mower from
one location to another. Watch for traffic when operating near or crossing roadways.
• Use care when approaching blind corners,
shrubs, trees, or other objects that may obscure
your vision.
Using a Ramp
 Exercise extreme caution when loading and unloading
a mower onto a truck or trailer with a ramp.
 Use only a single, full width ramp; do not use individual
ramps for each side of the unit. Having a full width
ramp provides a surface for the mower frame to contact if the unit starts to tip backwards. It also reduces
the risk of a wheel going off and the mower tipping
over.
 Do not exceed a 15 degree angle between the ramp
and the ground or between the ramp and the trailer or
truck.
 Place the deck height adjustment lever in the transport
position before loading or unloading onto a truck or
trailer with a ramp.
 Avoid sudden acceleration when on a ramp.
Slope Operation
Slopes are a major factor in loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes
require extra caution. If you cannot back the mower up the
slope or if you feel uneasy on the slope; do not mow it.
REMINDER: Only operate on slopes of 15 degrees or less.
 Use extreme caution when operating on slopes.
 Watch for holes, ruts, bumps, rocks or other hidden
objects. Uneven terrain could overturn the mower. Tall
grass can hide obstacles.
 Remove obstacles such as rocks, tree limbs, etc.
 Keep all movement on slopes slow and gradual. Do not
make sudden changes in speed or direction.
 Do not operate on slopes above retaining walls, dropoffs, drainage ditches, embankments, water, and other
types of hazards to avoid a wheel dropping over the
edge or to avoid the ground from breaking away. This
will reduce the risk of the mower suddenly rolling over
causing serious injury or death.
 Do not operate on wet grass. Slippery conditions
reduce traction which could cause sliding and loss of
control.
 Do not try to stabilize the mower by putting your foot
on the ground.
 Never make sudden starts, stops, turns, or reversals of
direction, especially when maneuvering on slopes. The
steering is designed for sensitive response. Rapid
movement of the steering control levers in either direction could result in a reaction of the mower that can
cause serious injury.
 Do not back down slopes. This action may result in a
reaction of the mower (tipping rearward) that can
cause serious physical injury.
 The Hustler® mower is capable of operating horizontally (traverse) on moderately steep slopes. When
operating on slopes up to 15 degrees, be aware of any
conditions that may cause the mower drive tires to
lose traction resulting in a possible loss of control of
the mower. Operators should not operate on a slope
until they are thoroughly familiar with the equipment.
Do not operate on slopes greater than 15 degrees.
Refer to the Slope Guide, when determining the degree
of slope to be mowed.
If the mower’s tires lose traction when operating on
slopes, turn the engine off, if possible, and step off the
operator’s platform to the uphill side.
After the mower stops:
• disengage the deck clutch,
• place the steering control levers in the neutral
position,
• engage the park brake,
• Be extremely careful changing directions on a
slope. Slow down.
• remove the ignition switch key, and
• Do not operate where the mower could slip or tip.
• get assistance.
• Turn slowly.
Wait until the condition that caused the problem is
resolved before attempting to operate on the slope
again.
• Turn on the most level part of the slope.
• Never operate the machine on a slope from a
position below the mower.
Terrain conditions can affect traction resulting in possible loss of control of the mower. Some of the conditions to be aware of are:
• When turning downhill, turn slowly and gradually.
 Do not remove or modify the stabilizer wheels.
606278
• Wet terrain
2-3
REV A
• Grass type, density, and height
 Never carry children, even with the blades off. They
may fall off and be seriously injured or interfere with
safe mower operation. Children who have been given
rides in the past may suddenly appear in the mowing
area for another ride and be run over or backed over by
the mower.
• Extremely dry conditions of grass
 Never allow children to operate the mower.
• Tire pressure
 Use care when approaching blind corners, shrubs,
trees, the end of a fence or other objects that may
obscure vision.
• Depressions in the ground; i.e. holes, ruts, washouts
• Mounds of dirt
• Soil type; i.e. sand, loose dirt, gravel, clay
Any attachments mounted to the mower will also
affect the way it handles on a slope. Be aware that
each attachment’s characteristics vary.
Another consideration for safe operation on slopes is
to be aware of what is located at the bottom of the
slope. Extreme caution should be used when there is a
hazard located at the bottom of the slope. Some examples are:
Service Precautions
 Unless specifically required, DO NOT have the engine
running when servicing or making adjustments to the
mower.
• Park the mower on level ground.
• Water; i.e. lake, river
• Disengage the deck clutch.
• Cliffs, retaining walls
• Place the steering control levers in the neutral
position.
• Roads, highways
• Buildings
• Place the park brake lever in the engaged park
brake position.
• Rocks
These are just a few examples of situations when caution must be used when operating on a slope. There
are many other possibilities too numerous to mention.
Just remember to always exercise extreme caution
when operating on any slope.
• Lower the deck.
• Stop the engine.
• Remove the ignition key.
• Wait for all movement to stop before adjusting,
cleaning or repairing.
Children
• Disconnect the negative battery cable.
Tragic accidents can occur if the operator is not alert to the
presence of children. Children are often attracted to the mower
and the mowing activity. Never assume that children will remain
where you last saw them.
• Repairs or maintenance requiring engine power
should be performed by trained maintenance personnel only.
 Never leave the mower unattended with the ignition
key in the switch, especially with children present.
 Children or bystanders may be injured if they attempt
to move or to operate the mower while it is unattended. Before leaving the operator’s platform:
• Disengage the deck clutch.
• Read and observe all safety warnings in this manual.
 Before working on or under the deck, make certain the
engine cannot be accidentally started.
 Always keep belt covers on mower deck for safety as
well as for cleanliness except when changing or checking the belt.
• Place the steering control levers in the neutral
position.
 Use a stick or similar instrument to clean under the
mower making sure that no part of the body, especially
arms and hands are under the mower.
• Place the park brake lever in the engaged park
brake position.
• Stop the engine.
 Always wear adequate eye protection when:
• Remove the ignition key.
 Keep children out of the mowing area and under the
watchful care of a responsible adult other than the
operator.
 Be alert and turn the mower off if children enter the
area.
 Before and while backing, look behind and down for
small children.
REV A
• To prevent carbon monoxide poisoning, operate
the engine in a well ventilated area only.
2-4
• servicing the hydraulic system.
• servicing the battery.
• grinding mower blades and removing accumulated debris.
 Never attempt to make any adjustments or repairs to
the mower drive system, mower deck or any attachment while the mower engine is running or deck clutch
is engaged. Repairs or maintenance requiring engine
606278
power should be performed by trained maintenance
personnel only.
 Never work under the machine or attachment unless it
is safely supported with jack stands.
• Make certain machine is secure when it is raised
and placed on the jack stands.
Battery Service Precautions
 Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the
State of California to cause cancer and reproductive
harm. Wash hands after handling.
 Charge batteries in a well-ventilated open area, away
from sparks and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.
• The jack stands should not allow the machine to
move when the engine is running and the drive
wheels are rotating.
 Avoid skin and clothing contact with battery acid.
• Use only certified jack stands. Use only appropriate jack stands, with a minimum weight rating of
2000 pounds (907 kg) to block the unit up.
• Always wear eye protection when checking the
battery. Acid can cause serious injury to skin and
eyes. If contact occurs, flush area with clean
water and call a physician immediately. Acid will
also damage clothing.
• Use in pairs only.
• Follow the instructions supplied with the jack
stands.
 Exercise caution when releasing spring tension from
any of the belt idlers or when working with any of the
deck lift components.
 Do not touch hot parts of machine.
 Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good working condition.
 Never tamper with safety devices. Check their proper
operation regularly.
 Grass collection system components are subject to
wear, damage and deterioration, which could expose
moving parts or allow objects to be thrown. Frequently
check components and replace with manufacturer’s
recommended parts, when necessary.
 Exercise caution when working under the deck as the
mower blades are extremely sharp. Wrap the blade(s)
or wear gloves and use extra caution when servicing
them.
• Do not drink the battery electrolyte.
• Do not allow open flame near the battery when
charging.
• Hydrogen gas forms inside the battery. This gas
is both toxic and flammable and may cause an
explosion if exposed to flame. Always disconnect
the negative (black) battery cable(s) before disconnecting the positive (red) cable(s). Always
connect the positive (red) battery cable(s) before
connecting the negative (black) cable(s).
• Do not overfill the battery.
• Electrolyte may overflow and damage paint, wiring or structure. When cleaning the battery, use
soap and water. Be careful not to get soap and
water into the battery. Clean the battery terminals with a solution of four parts water and one
part baking soda when they become corroded.
 Use only genuine Hustler® replacement parts to ensure
that original standards are maintained.
 Shorts caused by battery terminals or metal tools
touching metal mower components can cause sparks.
Sparks can cause a battery gas explosion which will
result in personal injury.
• The mower may not comply with the appropriate
safety standards if aftermarket parts, accessories, or attachments are used.
• Prevent the battery terminals from touching any
metal mower parts when removing or installing
the battery.
• Do not allow metal tools to short between the
battery terminals and metal mower parts.
Mower Blade Maintenance Precautions
 Never attempt to straighten a bent blade by heating, or
weld a cracked or broken blade as the blade may break
and cause serious injury. Replace worn or damaged
blades.
 Incorrect battery cable routing could cause damage to
the mower and battery cables. This can cause sparks
which can cause a battery gas explosion which will
result in personal injury.
 Never work with blades while engine is running or deck
clutch switch is engaged (on).
• Always disconnect the negative (black) battery
cable(s) before disconnecting the positive (red)
cable(s).
 Always wear adequate eye protection when grinding
mower blades.
 Mower blades are sharp and can cut. Wrap the
blade(s) or wear gloves and use extra caution when
servicing them.
606278
2-5
• Always connect the positive (red) battery cable(s)
before connecting the negative (black) cable(s).
REV A
Fuel Handling Precautions
 To avoid personal injury or property damage, use
extreme care when handling gasoline. Gasoline is
extremely flammable and the vapors are explosive.
• If gasoline is spilled on clothing, change clothing
immediately.
Safety and Instructions Decals
The decals are designed to give the operator and mechanic
brief daily operational and service information. Use these
decals as an extension of this manual. Do not remove or
obliterate the decals. Replace unreadable or missing decals.
• A fire or explosion from gasoline can burn you
and others and can damage property.
 Observe the usual gasoline handling precautions:
• Do not smoke while refueling. Extinguish all cigarettes, cigars, pipes and other sources of ignition.
It is the owner’s responsibility to make certain that the
operators and mechanics read and understand all decals
before operating this machine.
• Do not remove fuel cap or fill tank with engine running or while engine is hot. Clean up any gasoline
spills.
WARNING
• If gasoline is spilled, do not attempt to start the
engine but move the machine away from the area
of spillage and avoid creating any source of ignition until gasoline vapors have dissipated.
• Keep gasoline away from open flame or spark and
store machine away from open flame or spark or
pilot light such as on a water heater or appliances.
Specific safety warning decals are located on the
equipment near the immediate areas of potential
hazards. Do not remove or obliterate these decals.
Replace them if they become non-readable.
The following illustrations show the safety decals that are
located on the mower. A brief explanation is shown to help
the operator understand the decal’s meaning.
• Refuel outdoors. Never refuel or drain the gasoline from the machine indoors.
• Never attempt to start the engine when there is a
strong odor of gasoline fumes present. Locate
and correct the cause.
• Store gasoline in an approved container and keep
it out of the reach of children. Never buy more
than a 30-day supply of gasoline.
• Read Operator’s Manual and Safety Warning Decals before
attempting to operate this machine.
% E ANO
TH
L
S
• When practical, remove the machine from the
truck or trailer and refuel the machine with its
wheels on the ground. If this is not possible, then
refuel such machine on the truck or trailer using a
portable container and not a fuel dispenser nozzle. If a fuel dispenser nozzle must be used, keep
the nozzle in contact with the rim of the fuel tank
or container opening at all times until fueling is
complete. Do not use a nozzle lock-open device.
IN F UEL
N
HI G H ER T H A
0 F U V OI D
EL
WA M A X O F
RR A NT Y
10
E1
• Do not fill fuel containers inside a vehicle or on a
truck or trailer bed with interior carpets or plastic
truck bed liners. Always place gasoline containers on the ground away from your vehicle before
filling.
• Do not smoke while refueling.
• Do not remove the fuel tank cap or fill tank with engine running or
•
•
•
•
•
• Never use gasoline for cleaning parts.
• Read and observe safety precautions elsewhere
in this manual.
while the engine is hot.
Allow engine to cool before storing machine inside a building.
Store away from open flame or spark if there is fuel in tank.
Clean up any gasoline spills.
Do not refuel while in enclosed trailer or other enclosed areas.
Maximum of 10% ethanol (E10) in fuel. Fuels with greater than 10%
ethanol, (such as E15, E20 and E85) voids warranty. Fuels with
greater than 10% ethanol are not approved for use and such illegal
use could cause equipment failure and pose a fire hazard.
 Gasoline is harmful or fatal if swallowed.
 Avoid prolonged breathing of vapors.
• Long-term exposure to vapors can cause serious
injury and illness.
601058
WARNING:
Hot surface!
 Keep gasoline away from eyes and skin.
• Keep face away from nozzle and fuel tank or fuel
container opening.
REV A
• Avoid skin contact with hot surface.
Part Number 601058
2-6
606278
Park brake disengaged position
602041
Part Number 602041
• Keep a safe distance from the machine.
WARNING:
Hot surface!
Park brake engaged position
601906
Part Number 601906
606323
WARNING: Fire!
• Clean flammable material from
machine. Prevent fires by keeping
engine compartment, top of deck,
exhaust area, battery, fuel line, fuel
tank and operator’s station clean of
accumulated trash, grass clippings,
and other debris. Always clean up
spilled fuel and oil.
Part Number 606323
DANGER: Battery Hazards!
Part Number 601815
601815
• Avoid skin contact with battery
acid
• Do not overfill battery.
• Electrolyte may overflow and damage
•
606278
paint, wiring or structure. When cleaning
the battery, use soap and water. Be careful not to get soap and water into the
battery. Use soda mixed in water to
clean corrosion off the terminals.
Always wear eye protection when checking the battery, acid can cause serious
injury to skin and eyes. If contact occurs,
flush area with clean water and call physician immediately. Acid will also damage clothing.
• Do not allow open flame near the
battery when charging.
• Hydrogen gas forms inside the battery. This gas is both toxic and flammable and may cause an explosion if
exposed to flame. Always remove
the negative ground first and replace
it last.
2-7
REV A
WARNING: Thrown objects!
• Never operate the mower deck with side
deflector damaged, altered, removed or in
raised position, except when the entire
grass catcher attachment or mulching
system is being used.
DANGER:
Rotating blades, pulleys & belts
• Keep shields and covers in place
while machine is in operation.
• Keep hands, feet and clothing
606151
away from rotating pulleys and
belts.
Part Number 606151
WARNING: Thrown objects!
DANGER:
Rotating blades, pulleys & belts
• Always maintain a safe distance from
• Keep shields and covers in place
•
•
people and pets when mowing.
Always stop machine if someone enters
the area.
Inspect area to be mowed for hazards
such as rocks, metal objects and other Part Number 604222
debris which may be thrown or entangled
by mower blades. Remove these objects
before mowing.
while machine is in operation.
604222
• Keep hands, feet and clothing
away from rotating pulleys and
belts.
Part Number 606320
Part Number 606155
A
A
D
C
C
E
606155
A.
B.
C.
D.
E.
REV A
D
B
B
606320
Fast
Slow
Choke
For maximum electric clutch life engage at 1/2 - 3/4
throttle position.
For maximum electric clutch life disengage at low
throttle position.OFF
A.
B.
C.
D.
2-8
Fast
Slow
For maximum electric clutch life engage at 1/2 - 3/4
throttle position.
For maximum electric clutch life disengage at low
throttle position.
606278
Top of Deck Clutch Switch Shown
B
A
A.
B.
Deck clutch disengaged (OFF) position
Deck clutch engaged (ON) position
Part Number 606215
G
D
B
N
K
1.
2.
606215
A
C
E
F
H
I
A. WARNING: Read Operator’s Manual and decals before attempting
to operate this machine.
B. WARNING: Roll over!
C.
• Mow a safe distance (minimum of 10 feet) away from dropoffs, retaining walls, drainage ditches, embankments, water,
and other types of hazards to avoid a wheel dropping over the
edge or to avoid the ground from breaking away.
D. WARNING: Back over!
E.
• Do not carry passengers.
• Always stop machine if someone enters the area.
F.
• Always be aware of what is behind the machine before backing up. Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while backing up.
606278
2-9
J
L
M
O
G. WARNING: Roll over!
H.
• Slow down before turning.
I.
• Do not operate on slopes greater than 15 degrees.
• Keep all movement on slopes slow and gradual. Never make
sudden changes in speed and direction.
J.
• Do not operate on slopes above a retaining wall or drop-off.
K. WARNING: Loss of traction/control on slopes!
L.
• Shut off blades.
M.
• If the mower’s tires lose traction when operating on slopes,
turn the engine off, if possible, and step off the operator’s
platform to the uphill side.
N. WARNING: Ejection!
O.
• Go across slopes, not up and down.
• Never operate the machine on a slope from a position below
the mower.
REV A
Part Number 606264
E
G
H
A
I
J
B
606264
A
A.
B.
C.
C
D
Read Operator’s Manual before attempting to operate
this machine.
Wear ear protection, eye protection and safety shoes
with slip-resistant soles when operating this
equipment.
Before starting the engine:
• Read Operator’s Manual
• Disengage mower blades
• Place steering control levers in the neutral position
• Place park brake lever in engaged park brake position
Part Number 606154
F
D.
E.
F.
G.
H.
I.
J.
Before servicing:
• Read Operator’s Manual
• Disconnect spark plug before servicing
If warning light comes on, check engine oil.
Mower blade engage/disengage switch
Ignition switch - insert key
OFF
ON
Engine start position
E
G
H
A
I
J
B
606154
C
A.
B.
C.
REV A
D
F
Read Operator’s Manual before attempting to operate
this machine.
Wear ear protection, eye protection and safety shoes
with slip-resistant soles when operating this
equipment.
Before starting the engine:
• Read Operator’s Manual
• Disengage mower blades
• Place steering control levers in the neutral position
• Place park brake lever in engaged park brake position
2-10
D.
E.
F.
G.
H.
I.
J.
Before servicing:
• Read Operator’s Manual
• Disconnect spark plug before servicing•
If warning light comes on, check engine oil.
Mower blade engage/disengage switch
Ignition switch - insert key
OFF
ON
Engine start position
606278
Slope Guide
Use this diagram when determining the degree of slope to be mowed.
E (15o)
Slope Guide Lines
D (10o)
Line B
C (5o)
Line A
606278
1.
Hold this sheet of paper in front of you. Make sure that Line A is horizontal.
2.
Align Line B with a vertical surface such as pole, tree or building.
3.
Fold the paper along the slope guide lines (C, D or E).
4.
Align the closest slope guide line with the ground slope. This will give you a close estimation of the ground slope to
be mowed.
2-11
REV A
REV A
2-12
606278
OPERATION
Safe Operating Practices
B.
Ignition switch (Figure 3-1 & Figure 3-2) — a three
position switch: “OFF”, “RUN”, and “START”. With key
inserted, rotate it clockwise to the “START” position;
release the key when the engine starts, and the switch
will automatically return to the “RUN” position.
C.
Throttle control (Figure 3-1 & Figure 3-2) — a cable is
linked to the engine throttle for controlling engine
speed. Move the lever forward to increase engine rpm,
move the lever rearward to decrease engine rpm.
D.
Choke control (if equipped) (Figure 3-1) — a cable is
linked to manually operate the engine choke. When the
knob is in the down position, the choke is in the “OFF”
(run) position. When the knob is pulled up, the choke is
in the “ON” (start) position. Do not operate the machine
in the “ON” (start) position.
E.
Electronic hour meter (Figure 3-1 & Figure 3-2) — registers 1/10 hour increments up to 9,999.9 total hours. It
is connected to the ignition switch. It records the
accumulative time while the ignition key is switched to
the “RUN” position.
F.
Oil pressure light (Figure 3-1 & Figure 3-2) — this light
comes on when the ignition switch is placed in the
“RUN” position and stays lit until the engine is running
and a safe oil pressure is developed. If the light comes
on during operation, shut the engine off immediately
and locate and correct the problem.
G.
Engine malfunction light (Figure 3-2) — this light comes
on when there has been an engine malfunction on
mowers with electronic fuel injected engines. Refer to
the engine owner’s manual for more details.
H.
Fuel gauge (Figure 3-3) — This gauge shows the fuel
level in the fuel tank.
Refer to the Safety section of this manual for detailed operational and personal safety information.
Control Panel
Mowers with Kawasaki engines
A
C
D
F
A. Deck clutch switch
B. Ignition switch
C. Throttle
B
E
D. Choke
E. Hour meter
F. Oil pressure light
Figure 3-1
Mowers with Kohler engines
H
A
F
C
B
E
G
A.
B.
C.
D.
Deck clutch switch
Ignition switch
Throttle
N/A
E. Hour meter
F. Oil pressure light
G. Engine malfunction
light
H. Fuel gauge
Figure 3-2
A.
606278
Deck clutch switch (Figure 3-1 & Figure 3-2) — this
switch engages the deck. Pull the switch up to engage
and push the switch down to disengage the clutch.
For additional clutch information refer to the Mower
Deck Operation section of this manual.
3-1
Figure 3-3
Controls
A.
Steering control levers (Figure 3-4) — these levers
control the mower’s speed, direction, and stopping.
REV A
B.
Park brake lever (Figure 3-5) — Push the lever back and
down to engage the park brake. Pull the lever up and
forward to release the park brake.
Deck height adjustment lever shown in the transport
position.
WARNING
B
C.
The parking brake may not hold the mower if
parked on a slope. Block or chock the machine
when parked on a slope.
C
Deck height adjustment lever (Figure 3-5) — the deck
height adjustment lever is used to raise or lower the
deck. Place the deck height adjustment lever in the
transport position. Pull the adjusting pin out of the
hole that it is in and insert it into the desired cutting
height hole. Slide the deck height adjustment lever out
of the transport position and move the lever until it
rests against the adjusting pin.
D
Place the deck height adjustment lever in the transport
position when driving the mower from one location to
another with the blades disengaged (OFF).
B. Park brake lever
C. Deck height adjustment lever
D. Adjusting pin
Figure 3-5
Safety Start Interlock System
A
The mower’s safety start interlock system consists of the
park brake switch, operator presence switch, deck clutch
switch, and neutral switch.
IMPORTANT: Repair this important safety feature immediately if it malfunctions.
This safety feature prevents mower runaway or accidental
entanglement during operation.
A. Steering control levers
Check the mower’s safety start interlock system daily,
prior to operation.
Figure 3-4
There are three different system checks to perform.
System Check 1
Checking the operator presence switch and deck clutch
switch
REV A
3-2
1.
Stand on the operator’s platform when testing the
operator presence switch.
2.
Place both steering control levers in the neutral position.
3.
Place the park brake lever in the engaged park brake
position.
4.
Start the engine and allow it to warm up to operating
temperature.
606278
With the deck clutch switch down (deck blades disengaged), slowly step off the operator’s platform. The
engine should continue to run.
6.
Stand on the operator’s platform again and move the
park brake lever to the disengaged position.
7.
Pull the deck clutch switch up (deck blades engage).
8.
With the deck clutch switch up (deck blades engaged),
slowly step off the operator’s platform. The engine
should stop.
If the engine fails to function as it should in either Step 5 or
Step 8 contact your Hustler® Dealer to replace the operator
presence switch. System Check 2
Checking the park brake switch
1.
Stand on the operator’s platform when testing the park
brake switch.
2.
Place both steering control levers in the neutral position.
3.
Place the park brake lever in the disengaged park
brake position.
4.
5.
With the deck clutch switch down (deck blades disengaged), try to start the engine. The engine should not
start.
Engine Starting
The mower’s safety start interlock system is also designed
to protect the operator and others from accidental injury due
to unintentional engine starting. The engine starting motor
will not engage until:
1.
The park brake lever is in the engaged park brake position.
2.
The steering control levers are in the netural position.
3.
The deck clutch switch is in the down (deck blades disengaged) position.
WARNING
5.
Start the engine by following these steps. If you encounter
difficulty, contact your Hustler® Dealer.
1.
Make sure the park brake lever is in the engaged park
brake position, the steering control levers are in the
neutral position and the deck clutch switch is disengaged (mower blades disengaged). Start the engine
from the operator’s position only.
2.
Use the choke, if the unit is equipped with one, when
the engine is cold, or if a warm engine fails to start
within 5 seconds of cranking. Avoid flooding by operating the engine without choking as soon as possible.
3.
Set the throttle at approximately the 1/2 open position.
4.
Insert the key in the ignition switch and rotate it clockwise to engage the starting motor. Release the key
when the engine starts.
If the engine starts, contact your Hustler® Dealer to
replace the park brake switch.
System Check 3
Checking the neutral switch
NOTE: The brake switch must be working properly before
the neutral switch can be checked.
Stand on the operator’s platform.
2.
Set both steering control levers in the neutral position.
3.
Place the park brake lever in the engaged park brake
position.
4.
Start the engine and allow it to warm up to operating
temperature.
5.
Move one of the steering control levers out of the neutral position. The engine should stop.
6.
Re-start the engine.
7.
Move the other steering control lever out of the neutral
position. The engine should stop.
8.
If the engine fails to stop contact your Hustler® Dealer to
replace the neutral switch.
WARNING
1.
606278
The safety interlock system should always function per the above System Checks. If it does not
function properly, correct it immediately. Do not
operate machine without a properly functioning
operator presence switch, neutral switch, or park
brake switch.
The safety interlock system must not be disconnected or bypassed. Doing so could cause the
machine to operate unexpectedly resulting in personal injury.
IMPORTANT: The engine starter should not be operated for periods longer than 30 seconds at a time. At
least two minutes between such cranking periods to
protect the starter from overheating and burning-out.
5.
As soon as the engine begins to run, check to make
certain all engine warning lights are off. If not, stop the
engine immediately and check for the cause.
6.
Perform the test shown in the Safety Start Interlock System section to make sure the safety start interlock system operates properly.
7.
Allow the engine to idle two minutes before advancing
the throttle and/or engaging the deck clutch.
Stopping the Engine
Use the following procedure to shut the engine off.
1.
3-3
Place the steering control levers in the neutral position.
REV A
Throttle the engine back to low idle, then disengage
the deck clutch. Refer to the Mower Deck Operation section for more details.
3.
Place the park brake lever in the engaged park brake
position.
4.
Let the engine run at low idle for two minutes.
5.
Rotate the ignition key counter-clockwise to the “OFF”
position. Remove the key from the switch before leaving the mower.
Mower Operation
Driving the Mower
DANGER
2.
Moving the Mower With Stalled Engine
If it becomes necessary to move the mower when the
engine is inoperative, the hydraulic pumps are equipped with
bypass valves. Figure 3-6
The bypass valve is located near the top on each hydraulic
pump and is identified as a hex stud.
Before moving the unit:
Never make sudden stops or reverse direction,
especially when maneuvering on a slope. The
steering is designed for sensitive response. Rapid
movement of the control levers in either direction
could result in a reaction of the mower that can
cause serious injury.
After starting the engine, engage the steering control
levers and steer as follows:
To go forward, push the steering control levers forward an
equal distance. Figure 3-7
To go in reverse, pull the steering control levers rearward
an equal distance. Figure 3-7
• Rotate the bypass valves counterclockwise one-half to
one revolution. Figure 3-6
To turn left, move the right steering control lever farther
forward from neutral than the left steering control lever.
• Place the steering control levers in the neutral position.
To turn right, move the left steering control lever farther
forward from neutral than the right steering control lever.
Figure 3-7
• Place the park brake lever in the disengaged position
to release the park brake.
Do not tow the machine. Move it by hand or use a winch to
load on a trailer for transporting.
When transporting on another vehicle, the mower should
be facing forward and it must be secured.
Close the fuel shut-off valve when transporting or storing
the mower.
To stop or decrease speed, move steering control levers to
neutral. When going forward pull back gently on steering control levers. When going in reverse push forward gently on
steering control levers.
For emergency stops, when traveling forward or rearward,
place the steering control levers in the neutral position and
move the park brake lever to the engaged park brake position
immediately.
DANGER
Always make certain the two bypass valves are returned to
their operating position before attempting to use the mower
following repairs.
Zero radius turn, move one steering control lever forward
and the other steering control lever back of neutral. This
allows the drive wheels to counter-rotate. Figure 3-7
A
When moving in the rearward direction push forward gently on steering control levers and avoid
sudden movement. Any sudden movement could
cause the front of the mower to come off of the
ground resulting in possible loss of control, causing serious injury or death.
To make a three point turn to the right:
A. Bypass valve hex stud
1.
Move the left steering control lever farther forward
from neutral than the right steering control lever and
start the turn. Figure 3-8
2.
Next, pull back on the steering control levers until they
pass neutral and the machine starts to go rearward.
Figure 3-8
3.
Pull the right steering control lever farther rearward
from neutral than the left steering control lever until
the rear of the machine pivots around. Figure 3-8
4.
Then, push the steering control levers forward until
they both pass neutral and the machine starts to go
forward. Figure 3-8
Figure 3-6
REV A
3-4
606278
WARNING
5.
Push the left steering control lever farther forward
from neutral than the right steering control lever and
finish the turn. Figure 3-8
Always be aware of what is behind the machine
before backing up. Do not mow in reverse unless
absolutely necessary. Always look down and
behind before and while backing up.
FRONT OF MOWER FACES THIS DIRECTION
FORWARD TRAVEL
N
N
IMPORTANT: Damage to the hydraulic system components may occur with rapid movement of the steering controls.
To increase speed, increase the steering control lever’s distance from neutral. The farther forward the steering control
levers are from neutral, the faster the mower will travel forward. The farther back the steering control levers are from
neutral, the faster the mower will go in reverse.
ZERO RADIUS TURN
N
N
FORWARD TRAVEL
RIGHT TURN
N
N
N
N
REVERSE TRAVEL
RIGHT TURN
REVERSE TRAVEL
N
N
N = NEUTRAL POSITION
Direction of arrows indicate direction of mower
movement
Figure 3-7
606278
3-5
REV A
Operating Suggestions
THREE POINT TURN
DANGER
An inexperienced operator should not operate on
slopes or on uneven terrain.
Before attempting normal speed operation an inexperienced operator should:
• be thoroughly familiar with the proper use
and operation of the equipment.
• read the manual completely and thoroughly.
t
gh l
R i t ro
n
co ever
l
Ne
ut
ra
l
WARNING
ft
Le ro l
nt
co ever
l
Step 1
If you lose steering control while operating the
mower, turn the engine off and, if on a slope, step off
of the operator’s platform to the uphill side. Inspect
the machine and involve your Hustler® Dealer to
resolve the problem before continuing to operate.
WARNING
• have attempted slow moving maneuvers.
The unit’s steering control levers are very responsive: Easy does it! For smooth operation, move the
levers slowly, avoiding sudden movement. Skill
and ease of operation come with practice and
experience. The machine can spin very rapidly.
Use caution when making turns and slow down
before making sharp turns.
Inexperienced operators may have a tendency to oversteer
and lose control. Practice slow maneuvers at low engine rpm
(idle) on a flat open area before attempting normal speed
operation.
Step 2
N
WARNING
eut
ral
L
c e ft
o
n
t
l ev r ol
er
R
i
c g ht
o
n
t
l ev ro l
er
Step 3
Sharp depressions or raised obstacles (such as
gutters or curbs) should not be directly
approached at high speed in an attempt to “jump”
them as the operator could be thrown from the
equipment. Disengage the deck clutch and raise
the deck to the transport position. Approach at a
slow speed and angle one drive wheel at the
obstruction. Continue at an angle until the wheel
clears and then pivot the opposite wheel around.
When turning on soft wet turf, keep both wheels rolling
either forward or backward. Pivoting on one stopped wheel
can damage turf, especially when mowing.
Set the throttle at full rpm for maximum performance. This
gives maximum power to the drive wheels and deck when
needed. The throttle setting directly controls blade speed.
Use the control levers to control ground speed rather than
engine rpm.
Neutral
Right control lever
Keep blades sharp. Many problems with incorrect cutting
patterns are due to dull blades or blades which have been
sharpened incorrectly. Information on sharpening blades is
listed in this manual’s maintenance section. Blade sharpness
should be checked daily.
Left control lever
Figure 3-8
REV A
3-6
606278
DANGER
DANGER
Never work with blades while the engine is running
or deck clutch switch is engaged (on).
Always place the deck clutch switch in the disengaged position, place park brake lever in the
engaged park brake position, turn the engine off
and disconnect the negative battery cable.
Never attempt to make any adjustments to the
mower deck while the engine is running or with the
deck drive clutch engaged. Mower blades cannot
be seen and are located very close to the deck
housing. Fingers and toes can be cut off instantly.
Block the mower up when you must work under it.
Discharge chute may vary from this illustration
Wear gloves when handling blades.
Always check for blade damage if the mower
strikes a rock, branch or other foreign object
during mowing!
A
Direct grass discharge to the right, away from the
unmowed area. Generally, this means using a pattern of left
turns. Avoid throwing grass discharge onto unmowed area.
Mowing clippings puts an unnecessary load on the unit and
reduces mowing efficiency.
When mowing a lawn for the first time cut grass slightly
longer than normal to avoid scalping uneven terrain. When
cutting grass taller than six inches, you may want to mow the
lawn twice to achieve a better quality of cut.
During normal mowing cut off only about 1/3 of the grass
blade.
Remember, grass grows at different rates at different
times of the year. Mow more often in the early spring to
maintain the same cutting height. As the growth rate slows
in midsummer, mow less frequently. If you cannot mow at a
regular interval, mow at a high cutting height; then mow
again two days later at a lower cutting height.
Raise the cutting height of the mower if the cutting width
of the mower is wider than the previous mower. This ensures
that uneven turf is not cut too short.
Raise the cutting height of the mower if the grass is
slightly taller than normal or if it contains a high degree of
moisture. Then mow it again with the cutting height set
lower.
WARNING
If the machine’s forward motion must be stopped while
mowing, a clump of grass clippings may drop onto your lawn.
To avoid this, move onto a previously cut area with the
blades engaged.
Never direct the discharge of material from the
mower deck toward bystanders.
• Never operate the mower deck with the discharge chute damaged, altered, removed, or
in the raised position, except when the entire
grass catcher attachment or mulching system is being used. Figure 3-9
A. Discharge chute
Figure 3-9
Deck Clutch Operation
Before beginning operation, check to make sure the deck
clutch switch is engaging and disengaging the blades properly.
WARNING
Alternate the mowing direction to keep the grass growing
straight and for better dispersion of the clippings.
Make sure that the area around and under the deck
is clear and that there are no bystanders in the
immediate area before proceeding.
To check the deck clutch switch:
1.
Start the engine and engage the deck clutch.
2.
With the deck clutch switch up (clutch engaged) and
the engine running, listen to confirm that the mower
blades are rotating.
3.
Now, push the deck clutch switch down (clutch disengaged), and with the engine running, listen to confirm
that the blades have stopped rotating.
4.
If the mower blades continue to rotate with the deck
clutch switch down, discontinue operation immediately and contact your Hustler® Dealer.
Follow these procedures to maximize clutch life.
1.
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3-7
Engage the clutch only when the throttle is set at
approximately 2/3 throttle and there is no load on the
REV A
blades. After clutch engagement, advance the engine
throttle to full rpm.
Engaging the deck clutch at high engine rpm or when
under heavy load (in tall grass, for example) can cause
belts and/or electric clutch to slip, resulting in premature
wear or possible damage.
2.
Deck height adjustment lever shown in the transport
position.
Disengage the clutch only when the throttle is set at
less than 1/2 throttle.
A
Never disengage the clutch with the engine running at
high rpm. Setting the throttle to less than 1/2 throttle
when disengaging the clutch will help extend clutch life.
Warranty will not be allowed for deck clutches that fail due
to improper engagement and disengagement practices.
Deck Cutting Height Adjustment
Deck cutting height is adjustable in 1/4" (6.4 mm) increments.
To adjust the cutting height, pull up on the deck height
adjustment lever and latch it in the deck transport position.
Pull the adjusting pin out of the hole that it is in and insert it
into the desired cutting height hole. Slide the deck height
adjustment lever out of the transport position and move it
until it rests against the adjusting pin. Figure 3-10
WARNING
When transporting the mower pull up on the deck height
adjustment lever and latch it in the deck transport position.
Also, when loading or unloading the mower onto a truck or
trailer place the deck in the transport position.
B
A. Deck height adjustment lever
B. Adjusting pin
Figure 3-10
48”/52” Front anti-scalp wheel
Always stop the mower before moving the deck
height adjustment lever to prevent the operator
from slipping or falling.
B
Anti-scalp Wheels
Anti-scalp wheels are standard on these mowers. These
wheels are designed to minimize scalping when mowing on
rough uneven terrain. Figure 3-11, Figure 3-12, & Figure 3-13
The anti-scalp wheels can be installed in two positions.
With the wheel mounted in the bottom hole, the wheel is
located 2.00" (50.8 mm) below the mower blades. This setting is preferred when mowing at cutting heights of 2.50"
(63.5 mm) or higher.
A
A. Anti-scalp wheel
B. Adjusting holes
Figure 3-11
When the wheel is mounted in the top hole, it is located
1.00" (25.4 mm) below the mower blades. This is the acceptable setting for mowing at cutting heights of 1.50" (38.1 mm)
or higher.
When adjusting the rear anti-scalp wheels, the wheel
should be in the same axle mount hole as the front anti-scalp
wheels.
REV A
3-8
606278
60” Front anti-scalp wheel
A
B
A
A. Anti-scalp wheel
B. Adjusting holes
Figure 3-12
48”/52”/60” Rear anti-scalp wheel
B
A
A. Lower adjusting hole
B. Rear center anti-scalp roller
Figure 3-13
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3-9
REV A
REV A
3-10
606278
MAINTENANCE & ADJUSTMENTS
Safe Servicing Practices
Blade spindle bolt bottom . . . . . . . . 118 . . . . . . . 160
Refer to the Safety section of this manual for more detailed
service safety information.
Service Introduction
Regular maintenance is the best prevention for costly
downtime or expensive, premature repair. The following
pages contain suggested maintenance information and
schedules which the operator should follow on a routine
basis. For more detailed information order the correct Parts
Manual and General Service Manual for your unit. Refer to
the Product Literature section of this manual for more information.
Remain alert for unusual noises, which could signal a problem. Visually inspect the machine for any abnormal wear or
damage. A good time to detect potential problems is while
performing scheduled maintenance service. Correcting the
problem as quickly as possible is the best insurance.
Clear away heavy build-up of grease, oil and dirt, especially
in the engine and hydraulic component areas; minute dust
particles are abrasive to close-tolerance engine and hydraulic assemblies.
Inspect mower daily for grass clippings and wire or string
tangles. The underside of the mower deck will collect a buildup of grass clippings and dirt, especially when grass is wet or
has high moisture content. This build-up will harden, restricting blade and air movement which will probably result in a
poorer quality of cutting. Therefore it should be removed routinely. To do this it will be necessary to raise and block the
deck using jack stands or blocks in the full up position.
Scrape the build-up off from underneath.
Wheel motor nut . . . . . . . . . . . . . . . . 230 . . . . . . . 312
Lug nuts only - It is recommended that these be checked
after the first 2 hours of operation, initially, every 50 hours
and following removal for repair or replacement.
For all other torques refer to the mower’s General Service
Manual for standard torque chart. See Product Literature section for ordering information.
For engine torque values, refer to the engine owner’s manual.
Tires
It is important for level mowing that the tires have the
same amount of air pressure. The recommended pressures
are:
Drive wheels . . . . . . . . . . . . . . . . . . .8-12 psi (55-83 KPa)
Only pneumatic tires are approved for the drive tires on this
mower. Warranty claims will be denied on any mower
equipped with non-pneumatic tires.
Lubrication
Use SAE multi-purpose grease.
Electrical System
IMPORTANT: Refer to the Safety section of this manual for
detailed battery servicing safety information.
The electrical system is a 12 volt, negative ground. The recommended battery size is:
Torque Values
A maintenance-free battery is recommended. Otherwise,
follow battery manufacturer’s maintenance, safety, storing
and charging specifications.
WARNING
Some repairs require the assistance of a trained service
mechanic and should not be attempted by unskilled personnel. Consult your Hustler® service center when assistance is
needed.
Particular attention must be given to tightening the
drive wheel lug nuts and blade spindle bolts. Failure
to correctly torque these items may result in the loss
of a wheel or blade, which can cause serious damage or personal injury.
Garden tractor BCI group U1R with a 225 or better
cranking AMP rating
System Fuses
The electrical system for this mower includes three fuses:
A.
Master in-line fuse (30 amp) – Main fuse to protect the
complete electrical system. It is located at the right
rear of the engine next to the solenoid. Figure 4-1
B.
Deck clutch fuse (15 amp) – This fuse protects the deck
clutch. It is located under the right front of the control
panel. Figure 4-2
C.
Ignition/Safety system fuse (10 amp) – This fuse protects the ignition and safety circuit components. It is
Torque values are given below:
ft-lbs
N•m
Wheel (lug) nuts . . . . . . . . . . . . . . . . . 70. . . . . . . . . 95
Blade spindle bolt top . . . . . . . . . . . . 73. . . . . . . . . 99
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4-1
REV A
located under the right front of the control panel.
Figure 4-2
Hydraulic System
WARNING
IMPORTANT: Never use hydraulic or automatic transmission fluid in this system; use only synthetic motor oil as
specified. Remember, dirt is the primary enemy of any
hydraulic system.
Hydraulic fluid escaping under pressure may have
sufficient force to penetrate skin and cause serious injury. Foreign fluid injected into the skin must
be surgically removed within a few hours by a doctor, familiar with this form of injury, or gangrene
may result.
Before applying pressure to hydraulic system,
make sure all connections are tight and all hoses
and lines are in good condition. To find a leak
under pressure, use a piece of cardboard or wood
— never use your hands. Relieve all pressure in the
system before disconnecting or working on
hydraulic lines. To relieve pressure, lower all
attachments and shut off engine.
A
A. Master fuse housing
Figure 4-1
Check oil level in hydraulic system after every 50 hours of
operation or weekly, whichever occurs first. The hydraulic
system must be cool when checking the oil level and the
mower should be on level ground. Check more often if system appears to be leaking or otherwise malfunctioning.
Use the hydraulic reservoir’s sight glass to check the reservoir fluid level. The hydraulic system must be cool and the
mower should be on level ground when checking the oil level.
The oil level should be approximately in the middle of the
sight glass. Figure 4-3
B
C
Only use full synthetic 15W50 oil in the hydraulic system.
NOTE: The reservoir (Figure 4-4) will require approximately
1.0 U.S. gallons (3.78 liters) of full synthetic 15W50 oil when
replacing the oil after an oil and filter change. Do not overfill
the reservoir.
B. 15 amp fuse
C. 10 amp fuse
Initial system oil and filter change must be after the first 50
hours of mower operation. Thereafter, replace filter and oil in
the reservoir every 500 hours.
Figure 4-2
IMPORTANT: It is necessary to drain the system oil from
the hydraulic reservoir, using the reservoir drain plug, before
removing the hydraulic filter. Replace the drain plug before
adding system oil.
The system filter is located at the left rear of the engine.
Use a Hustler® approved filter element only. When changing
the filter use a standard oil filter wrench. The threads are
right hand. Figure 4-5
Fuel and Evaporative Emissions Control System
IMPORTANT: Refer to the Safety section of this manual for
fuel handling safety information.
The fuel and evaporative emissions control system for this
mower is EPA compliant. Use only Hustler® approved
replacement parts.
REV A
4-2
606278
A
A
A. Hydraulic filter
Figure 4-5
• canister mounting brackets
• carburetor purge port connection
• filters
• vapor hoses
A. Sight glass
• clamps, control valves
Figure 4-3
• control solenoids
• electronic controls
• vacuum control diaphragms
• purge valves
• liquid/vapor separator
• other associated components
Modifying or Tampering with the evaporative emissions control system or the fuel system is prohibited. Federal law and
California State law prohibit the following acts or the causing
thereof:
A
1.
The removal or rendering inoperative by any person
other than for purposes of maintenance, repair,
replacement, of any device or element of design incorporated into any equipment for the purposes of emissions control prior to or after its sales or delivery to the
ultimate purchaser or while it is in use, or
2.
The use of the equipment after such device or element
of design has been removed or rendered inoperative by
any person.
A. Hydraulic reservoir
Your evaporative emission control system may include
parts such as:
• fuel tanks
• fuel lines
WARNING
Figure 4-4
Use of replacement parts not equivalent to the
original parts may result in system failure and
pose a safety hazard.
• fuel line fittings
• fuel caps
The fuel tank is located to the left of the operator platform.
• carbon canisters
606278
4-3
REV A
Park the mower on level ground before filling the fuel tank.
Clean the area around the fuel cap before removing the
cap. Remove the fuel cap slowly.
When threading the fuel cap onto the filler neck, tighten the
cap until it begins to click, then, continue to turn it until at
least three clicks are heard.
When closed the fuel shut-off valve prevents fuel flow to
the engine. Figure 4-7 or Figure 4-8
Mowers with Kawasaki engine
Valve shown in the open position
WARNING
IMPORTANT: Do not overfill the fuel tanks. The fuel tanks
should be filled no higher than the bottom of the fill neck.
(Figure 4-6) The fuel system is designed to leave room for the
fuel to expand with fuel temperature changes.
A
Overfilling the fuel tank may cause the following:
• Engine damage
• Fire hazard!
Fill to the bottom of the filler neck
A. Fuel shut-off valve
A
Maximum
Figure 4-7
B
Mowers with Kohler engines
Valve shown in the open position
Do Not
Overfill
A. Filler neck
B. Fuel tank
Figure 4-6
Use regular unleaded gasoline with an octane rating of 87
or higher. Maximum of 10% ethanol (E10) in fuel. Fuels with
greater than 10% ethanol (such as E15, E20 and E85) voids
warranty. Fuels with greater than 10% ethanol are not
approved for use and such illegal use could cause equipment
failure and pose a fire hazard.
A
Refer to the Engine Owner’s Manual for additional fuel specification requirements.
A. Fuel shut-off valve
Fuel Shut-off Valve
This mower is equipped with a fuel shut-off valve. It is
located under the right front of the control panel.
REV A
4-4
Figure 4-8
606278
Fuel Evaporation System Filter
These mowers have a fuel evaporation system filter. This
filter must be checked and replaced every 500 hours or annually whichever comes first. Figure 4-9
IMPORTANT: All oil drips or spills must be cleaned off
of the exhaust system before operating the machine.
Kawasaki engines
A
A
A. Oil drain valve
A. Fuel evaporation system filter
Figure 4-10
Figure 4-9
Kohler engines
WARNING
Engine Oil and Filter
Allow the engine to cool before changing the
engine oil. If the engine has been running, use caution when changing the engine oil as it will be very
hot. You should wear the appropriate protective
gear to avoid being burned or exposed to engine
oil.
Check the engine oil daily and after every 4 hours of operation. The mower must be level when checking the oil. Refer to
the Engine Owner’s Manual and maintenance schedule for oil
recommendation and capacities.
Change the engine oil and filter after the first 5 hours of
operation and per the engine manufacturer’s recommendations after that. Change the engine oil more frequently if
operating in extremely dirty conditions. IMPORTANT: When
removing the oil filter take precautions to minimize oil spillage on the exhaust system.
Draining the Engine Oil:
1.
Locate the oil drain valve on the engine. Figure 4-10 or
Figure 4-11
2.
Position a suitable oil drain container under the
machine below the oil drain valve.
3.
Twist the valve counterclockwise to open the valve.
Allow 10 minutes for engine oil to adequately drain.
4.
After oil is drained, close the valve by twisting it clockwise.
5.
Once the valve is closed, clean up any spilled oil.
606278
A
A. Oil drain valve
Figure 4-11
Engine Air Filter
These mowers come equipped with two different styles of
air filters; integrated or canister. The required servicing for
these two filter types is different from one to the other. Refer
to the following for the one appropriate for your mower.
Integrated type
Perform engine air filter maintenance per the Maintenance
Schedule shown elsewhere in this manual. Figure 4-12
Canister type
Perform engine air filter maintenance per the Maintenance
Schedule shown elsewhere in this manual.
4-5
REV A
Kawasaki FS541V engine
Kawasaki FX691V/FX730V engine
A
A
B
D
C
A. Air filter cover
Figure 4-12
A specially designed dry filter is standard equipment on
these mowers and supplies clean combustion air to the
engine. Figure 4-13 and Figure 4-14
These mowers are equipped with a safety filter. The filter
element slides over the safety filter. Figure 4-15 and
Figure 4-16
A. Pre-cleaner
B. Air cleaner canister
C. Dust cap
D. Clamp
Figure 4-14
Kohler ECV730/ECV740 engine
The safety filter does not require servicing unless it
becomes contaminated with dirt or moisture.
Kohler ECV730/ECV740 engine
d
C
A
A
D
A. Safety filter
B
Figure 4-15
A. Pre-cleaner
B. Air cleaner canister
looking for any holes or tears in the paper. Also check
gaskets for cuts or tears. Do not attempt to use a damaged element which will allow abrasive particles to
enter the engine.
C. Dust cap
D. Clamp
3.
Reinstall the dust cap. Make sure it seals all the way
around the air cleaner canister, then tighten the
clamps. Figure 4-13 and Figure 4-14
4.
Check all fittings and clamps periodically for tightness
and inspect hoses for holes or cracks.
5.
Periodically check the intake hose for signs of
ingested dust. Locate and repair the source of
ingested dirt.
Figure 4-13
Recommended service procedure
1.
Release clamps and remove element. Clean the air
cleaner canister with a damp cloth.
2.
Before installing a new element, inspect it by placing a
bright light inside and rotating the element slowly,
REV A
4-6
606278
Of course, at some point the filter media becomes too
clogged to allow air to pass.
Kawasaki FX691V/FX730V engine
The mowing conditions will determine the frequency of air
filter element changing.
General Engine Maintenance
Detailed instructions and recommendations for break-in
and regular maintenance are specified in the Engine Owner’s
Manual. Please refer to this manual for engine servicing,
lubricating oil levels with quality and viscosity recommendations, bolt torques, etc. The engine warranty is backed by the
manufacturer. Special attention should be paid to applicable
data which will not be duplicated here.
A
Belts
Inspect belts frequently for wear and serviceability.
Replace a belt that shows signs of:
A. Safety filter
• severe cuts
Figure 4-16
6.
• tears
Never operate the machine without an air filter
installed.
• separation
• weather checking
Overservicing
• cracking
Overservicing occurs when an air filter element is removed
for cleaning or replacement before it is necessary. Each time
the filter is removed a small amount of dirt and dust could
fall in the intake system. This accumulated dirt can cause a
dusted engine. It only takes a few grams of ingested dirt over
the normal service life of an engine to cause a dusted engine.
• burns caused by slipping.
It is important to note that whenever an air filter element is
cleaned by any method, the person or company performing
the cleaning assumes responsibility for the integrity of the
filter from then on. The warranty for air filters expires upon
cleaning or servicing in any manner because the condition of
the filter after servicing is completely out of the filter manufacturer’s control. Therefore, on a dust ingested engine failure,
there will be no warranty consideration if the air filter element
has been cleaned or serviced in any manner.
A partially dirty air filter element works better than a new
element. Therefore, a dirty filter element is not bad for the
engine unless it is excessively restricting the air flow and
engine performance is affected. The reason is simple. The
media in the filter must be porous to allow air to pass
through it. When dirty air passes through the filter, the dirt
plugs some of the holes in the media and actually acts as
part of the filter media. When the next round of dirt enters,
the first dirt helps filter out even smaller particles making the
filter more efficient at stopping dirt from entering the engine.
This is referred to as barrier filtration.
606278
4-7
WARNING
Do not clean the element, but replace with a new element
only. Cleaning used air filter elements, through improper
cleaning procedures, can get dust on the inside of the filter
causing dirt ingestion and engine failure.
Slight raveling of belt covering does not indicate failure,
trim ravelings with a sharp knife.
If the pump belt fails, loss of steering control will
occur especially when operating on a slope. If you
lose steering control while operating the mower, turn
the engine off and, if on a slope, step off of the operator’s platform to the uphill side. Inspect the
machine and involve your Hustler® Dealer to resolve
the problem before continuing to operate.
Inspect the belt pulley grooves and flanges for wear. A new
belt, or one in good condition, should never run against the
bottom of the groove. Replace the pulley when this is the
case, otherwise the belt will lose power and slip excessively.
Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt covering.
Keep oil and grease away from belts, and never use belt
dressings. Any of these will destroy the belt composition in a
very short time.
Mower Blade
Mower Blade Maintenance
IMPORTANT: Refer to the Safety section of this manual for
blade handling safety information.
REV A
WARNING
Refer to the Mower Blade Replacement section for blade
removal and installation.
Mower blades are sharp and can cut. Wrap the
blade(s) or wear gloves and use extra caution
when servicing them.
A
Check the mower blades daily, they are the key to power
efficiency and well groomed turf. Keep the blades sharp. A
dull blade will tear rather than cut the grass, leaving a brown
ragged top on the grass within a few hours. A dull blade also
requires more power from the engine.
Do not sharpen to original pattern (below). It
is easier to get a straight cutting edge following the re-sharpening pattern shown above.
Replace any blade which is bent, cracked or broken.
WARNING
Always check for blade damage:
• if mower strikes a rock, branch or other foreign object during mowing!
• or if an abnormal vibration occurs while operating.
B
Make all necessary repairs before resuming operation.
Sharpen the blades following the pattern shown. Touch-up
sharpening can be done with a file. Figure 4-17
After grinding the blades, check for balance. Blade balancing can be done by placing the blade on an inverted line
punch or 5/8" bolt. A commercial balancing tool is also available through most hardware supply stores.
A. Re-sharpening pattern
B. Original edge
Figure 4-17
End view of blades, comparing twisted and straightened blades.
D
The blade should not lean or tilt. When spinning the blade
slowly it should not wobble. Balance the blade before reinstalling.
Lay the blade on a flat surface and check for distortion.
Replace any distorted blade. Figure 4-18 & Figure 4-19
Comparison of Warped and Straight Blades
A
C
D
A
B
B
C
A. Twisted blade edge —
replace blade
B. Straight blade edge
C. Cutting plane
D. Cutting edge
Figure 4-19
A. Warped blade — replace
B. Straight blade
C. Cutting plane
Figure 4-18
REV A
4-8
606278
Mower Blade Replacement
The center spring is non-adjustable.
WARNING
IMPORTANT: Refer to the Safety section of this manual for
blade handling safety information.
Mower blades are sharp and can cut. Wrap the
blade(s) or wear gloves and use extra caution
when servicing them.
To adjust the springs:
1.
Loosen the lower nut enough to allow the spring to
move. Figure 4-21
2.
Tighten the lower nut after the spring is located in the
desired position. Figure 4-21
3.
Repeat for the other side.
A 15/16" wrench is required to remove the 5/8" cap screw
holding the blade to the spindle shaft. NOTE: A blade holding
tool (part number 381442) is available from Hustler ® Turf
Equipment. It is designed to prevent the blades from rotating
when they are being removed or installed on the spindle. Contact your Hustler® Dealer for more information.
C
B
A
A
WARNING
Do not re-use spindle bolts which have stripped, worn or
undercut threads. Torque bolts on spindles to 118 ft-lbs
(160.0 N•m) when reinstalling blades.
A. Side springs
B. Center spring
Failure to correctly torque the bolt may result in
the loss of the blade which can cause serious
injury.
C. Operator platform
Figure 4-20
Properly compressed cup washers maintain the correct
compression load on the blades. Replace the cup washers if
they are cracked or flattened.
C
B
IMPORTANT: The blade sail (curved part) must be pointing upward toward the inside of the deck to ensure proper
cutting.
When mounting blades, rotate them after installation to
ensure blade tips do not touch each other or sides of the
mower.
A
A
D
Operator Platform Adjustment
There are three springs that are located under the operator
platform. The two side springs can be adjusted forward or
rearward to allow for operator ride preference. Figure 4-20
A. Side springs
B. Center spring
C. Operator platform
D. Lower nut
Figure 4-21
These two springs should always be in line with each other.
No spring should be further forward or rearward than the
other.
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4-9
REV A
Maintenance Schedule
Figure 4-22, Figure 4-23, Figure 4-24, & Figure 4-25
WEEKLY
OR 50
HOURS
SERVICE AT
INTERVALS INDICATED
MONTHLY
OR 100
HOURS
ANNUALLY
OR 500
HOURS
Verify safety start interlock system
Prior to each use
Visually inspect unit for loose hardware and/or damaged parts
Prior to each use
Visually inspect tires
Prior to each use
Check oil level, engine (1)
Prior to each use or every 4 hours
Clean air intake screen (8)
Prior to each use or every 4 hours
Check fuel level
Prior to each use
Blades - sharpen & securely fastened
Prior to each use
Discharge chute - securely in place & in lowest position
Prior to each use
Clean engine and pump compartment
Daily
As needed
Replace air cleaner paper element (Kawasaki FS541V engines) (5)
Replace air filter (Kawasaki FX691V/FX730V and Kohler ECV730/ECV740 engines) (5)
Change engine oil and filter (1) (4)
As needed
X
Clean cylinder and head fins (a)
X
Check battery connections
X
Check tire pressure with a gauge
X
Check hydraulic oil level
X
Clean engine exterior (a)
X
Grease deck pusher arms (8)
X
Grease deck height pivots (8)
X
Grease front wheel bearings (8)
X
Clean & regap spark plugs (a)
X
Check pump and deck belt tension and condition (6)
X
Check fuel system (7)
X
Check hydraulic lines
X
Check fuel valve and grommets (7)
X
Tighten lug nuts on wheels (2)
X
Adjust park brake (9)
X
Change fuel filter (7)
X
Clean or replace hydraulic fill cap
X
Change hydraulic filter & oil (3)
X
Grease deck spindle housings
X
Replace spark plugs
X
Replace fuel evaporation system filter (8)
X
NOTES:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Initial oil change is after 5 hours of operation. Thereafter, change oil after every 40 hours operation. Change more often under dusty or dirty conditions and during hot weather periods.
Torque initially and after first 2 hours of operation.
Perform initial hydraulic oil and filter change after 50 hours (one week) of operation.
Change engine oil filter per the engine manufacturer’s recommendations. Refer to Engine Owner’s Manual for recommendations and other
maintenance items.
Service more often under dusty or dirty conditions. Use caution when servicing to prevent dust contamination in the engine. Do not clean filter
element. Replace with a new one.
Pump drive belt only - Inspect belt every 100 hours and replace if worn or cracking is noticed. Check spring tension adjustment. Otherwise,
replace belt every 400 hours or 2 years whichever comes first. Check and adjust spring tension after 50 hours of use as outlined in the Hydraulic
Pump Belt Adjustment section of the General Service Manual (122565).
Check fuel system for any crack or leaks including, but not limited to, fuel line hoses, fuel valve, vent line hoses, vent valve, vapor valve, carbon
canister, and grommets. Replace as needed.
More often under dusty or dirty conditions and during hot weather.
Check and adjust park brake per the General Service Manual (122565).
REV A
4-10
606278
10. Initial system oil and filter change must be after the first 50 hours of mower operation. Thereafter, replace filter and oil in the reservoir every 500
hours.
REFERENCES:
A. Refer to engine owner’s manual for engine service information.
NOTE: After completing maintenance cycle (500 hours), repeat cycle.
606278
4-11
REV A
Maintenance Locator Chart
Units with Kawasaki Engines
6
8 11
12
9
11
4
1
13
10
14
3
7
2
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
11
9
5
Figure 4-22
Units with Kohler Engines
6
8 11
9
11
4
13
12
10
Engine Oil Fill & Dipstick
Fuel Filter
Engine Air Cleaner
Engine Oil Drain Valve
Battery
Fuel Tank
Hydraulic Oil Reservoir
Hydraulic Oil Filter
Front Wheel Bearing Zerks (2)
Engine Oil Filter
Deck Height Pivot Zerks (4)
Drive Tire
Fuel Evaporation System Filter
Pump Belt
Deck Pusher Arm Zerks (2)
Deck Belt
Spindle Housing Zerk (3)
Blades
2
14
3
7
1
12
11
9
5
Figure 4-23
REV A
4-12
606278
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
14
Figure 4-24
Figure 4-25
18
15
17
Engine Oil Fill & Dipstick
Fuel Filter
Engine Air Cleaner
Engine Oil Drain Valve
Battery
Fuel Tank
Hydraulic Oil Reservoir
Hydraulic Oil Filter
Front Wheel Bearing Zerks (2)
Engine Oil Filter
Deck Height Pivot Zerks (4)
Drive Tire
Fuel Evaporation System Filter
Pump Belt
Deck Pusher Arm Zerks (2)
Deck Belt
Spindle Housing Zerk (3)
Blades
17
16
18
15
17
18
606278
4-13
REV A
REV A
4-14
606278
TROUBLESHOOTING
The majority of operating problems that occur with a system can be traced to improper adjustments or delayed service. A
consistently applied preventative maintenance program, as outlined in the Maintenance section of this manual, will prevent many
problems. The following chart is designed to help you locate a problem by suggesting probable causes and the recommended
solutions.
SYMPTOMS
Starting motor does not
crank
The engine will not start,
starts hard or fails to
keep running
PROBABLE CAUSES
Park brake lever not in park
brake position
Place park brake lever in
park brake position
Deck clutch switch
engaged
Disengage clutch switch
Weak or dead battery
Recharge or replace
Electrical connections are
corroded or loose
Check the electrical connections
Fuse is blown
Check fuses – replace
blown fuse
Neutral switches not
engaging
Move steering control lever
to neutral position or
adjust switches if necessary
For additional causes
See engine manual
No fuel or line plugged
Fill tank or replace line
(See Fuel System section
for more details)
Fuel valve is turned off
Open the fuel valve
There is incorrect fuel in
the fuel system
Drain the tank and replace
the fuel with the proper
type
There is dirt in the fuel filter
Replace the fuel filter
Dirt, water or stale fuel in
the fuel system
Contact your Dealer
The choke is not on
(if equipped)
Move the choke lever to ON
Numerous
See engine manual
Engine:
Runs with continuous
misfiring or engine runs
unevenly or erratically
Numerous
See engine manual
Loss of power or system
will not operate in either
direction
Restrictions in air cleaner
Service air cleaner
Poor compression
Contact your Dealer
Steering linkage needs
adjustment
Adjust linkage
Tow valve open
Close tow valve
Air cooled engine overheating
Low engine oil pressure
High oil consumption
606278
SYMPTOMS
SUGGESTED
REMEDIES
Mower jerky when starting or operates in one
direction only
Mower circles or veers in
one direction
There is abnormal vibration
Blades do not rotate
Uneven cutting height
PROBABLE CAUSES
SUGGESTED
REMEDIES
Steering control linkage
needs adjustment
Adjust linkage
Loose steering linkage
Tighten linkage
Tow valves not closed
completely
Close tow valves
Pump or wheel motors
faulty
Contact your Dealer
Steering linkage needs
adjustment
Adjust linkage
Loose steering linkage
Tighten linkage
Tires improperly inflated
Adjust air pressure to 8–12
psi (55–83 KPa)
Wheel motor faulty
Contact your Dealer
Hydraulic pump faulty
Contact your Dealer
The engine mounting bolts
are loose
Tighten the engine mounting bolts
The engine pulley, idler pulley or blade pulley is loose
Tighten the appropriate
pulley
The engine pulley is damaged
Contact your Dealer
The cutting blade(s) is/are
bent or unbalanced
Install new cutting blade(s)
A blade mounting bolt is
loose
Tighten the blade mounting bolt
Spindle bearing is worn or
loose
Replace or tighten spindle
bearing
A blade spindle mount is
bent
Contact your Dealer
The deck drive belt is worn,
loose or broken
Install a new deck drive
belt
The deck drive belt is off
the pulley
Install the deck drive belt
and check for a reason
Electric clutch is not
engaging
Check and/or replace 15
amp fuse.
Contact your Dealer
The blade(s) are not sharp
Sharpen the blades
Install new cutting blade(s)
The traction drive belt is
worn, loose or broken
Install a new traction drive
belt
A cutting blade(s) is/are
bent
Air in system
Check filter and fittings
The deck is not level
For additional causes
See engine manual
Level the deck per the Deck
leveling and height adjustment section of the General
Service Manual
Air intake screen or cleaning fins clogged
Clean screen and fin
An anti-scalp wheel is not
set correctly
Adjust the height of the
anti-scalp wheel
For additional causes
See engine manual
Low oil level
Add oil
The underside of the deck
is dirty
Clean the underside of the
deck
Oil diluted or too light
Change oil and check for
source of contamination
Tires improperly inflated
Adjust air pressure to 8–12
psi (55–83 KPa)
Failed oil pump
Contact your Dealer
A blade spindle mount is
bent
Contact your Dealer
Numerous
Contact your Dealer
5-1
REV A
REV A
5-2
606278
STORAGE
When storing the unit at the end of the mowing season, the
mower, engine, and battery should have the following items
serviced before storage.
8.
Clean the exterior surface of the engine. Spread a light
film of oil over any exposed metal surfaces of the
engine that are subject to corrosion.
If the mower has been stored for an extended period of
time, follow the new season preparation steps before beginning operation.
9.
Clean dirt and chaff from the cylinders and fins, blower
housing and muffler.
10.
Check the oil filler cap and fuel tank caps to make certain they are securely in place.
11.
Refer to the engine manual for more information.
General Mower Preparation for Storage
1.
Remove all grass, dirt, and trash from mower and cutting units.
IMPORTANT: Wash the machine with a mild detergent
and water. Do not pressure wash the machine. Avoid
excessive use of water, especially near the control
panel and engine.
Clean mower and deck and touch up all scrapes with
touch-up paint.
Preparation of Battery for Storage
When the machine is to be unused for long periods, it is
best to disconnect the battery and remove it from the unit. At
this time perform the following battery maintenance:
1.
Remove the battery from machine.
2.
Clean the battery, terminals, and cable connectors.
2.
Replace the air filter element.
3.
Charge the battery, if necessary.
3.
Check thoroughly for any worn or damaged parts that
need replacing and order them from your dealer.
4.
Store the battery in a cool, dry place (do not expose to
freezing temperatures).
4.
Thoroughly lubricate machine, according to the Maintenance section.
5.
5.
Block mower up so weight is off tires. Check tire pressure and inflate to proper operating pressure.
Always keep the battery fully charged. Especially
important to prevent battery damage when the temperature is below 32°F (0°C).
NOTE: Do not deflate tires.
6.
Perform separate engine and battery preparation as
listed below.
7.
Store mower in a clean, dry place.
New Season Preparation
Before starting the mower following post season storage,
the following service is required:
Clean mower, removing trash and dirt accumulation.
2.
Check engine oil and hydraulic oil levels.
Preparation of Engine for Storage
3.
When the engine is to be unused for long periods, proceed
as follows:
Install fully charged battery and attach the battery
cables.
4.
Fill fuel tank(s) with fresh fuel. Run machine at half
speed for 5 minutes, checking operation of steering
control lever. Stop engine and check for oil leaks,
loose fittings and so forth.
1.
Run the engine for a minimum of 15 minutes.
2.
Drain the oil from the crankcase while the engine is
still warm.
3.
Refill with fresh oil of the proper viscosity.
4.
Drain the fuel tank and run the engine until it stops
from lack of fuel. Close the fuel shut-off valve when
storing the mower.
Gasoline evaporates if left in the carburetor for long
periods, forming gum and varnish deposits in the
carburetor. These deposits will cause engine flooding
and loss of power.
5.
Remove and replace fuel filter if not done in previous
100 hours.
6.
Remove the spark plugs and pour a tablespoon of
engine oil into each spark plug hole. Install plugs and
reconnect plug leads.
7.
Crank the engine with the starter at least a dozen revolutions to distribute oil over the cylinder walls and
valve mechanism.
606278
6-1
WARNING
1.
At start of new season always check that fresh oil
has been added to machine. If oil is drained at season’s end and not replaced, engine damage will
result.
5.
Tighten any bolts that have loosened and make sure
all hair pins, cotter pins and clevis pins are in place.
6.
Install all safety shields and review safety precautions
listed in this manual.
7.
Check and inflate tires to 8–12 psi (55–83 KPa).
8.
Refer to engine manual for more information.
REV A
PRODUCT LITERATURE
If you would like to view or print a copy of the product manuals (Operator’s Manual, Parts Manual, or General Service Manual) for
these mowers go online to www.hustlerturf.com and click on the MANUALS button.
Contact your local Hustler® dealer if you require another engine manual.
REV A
6-2
606278
INDEX
PAGE
PAGE
Battery Service Precautions ...................................2-5
Mower Operation .................................................... 3-4
Belts .........................................................................4-7
New Season Preparation ....................................... 6-1
Children ...................................................................2-4
Operating Suggestions .......................................... 3-6
Control Panel ...........................................................3-1
Operation ................................................................ 2-2
Controls ...................................................................3-1
Operator Platform Adjustment ............................... 4-9
Deck Clutch Operation ...........................................3-7
Parts and Service ................................................... 1-1
Deck Cutting Height Adjustment ............................3-8
Personal Safety ...................................................... 2-1
Draining the Engine Oil ..........................................4-5
Preparation of Battery for Storage ........................ 6-1
Driving the Mower ...................................................3-4
Preparation of Engine for Storage ........................ 6-1
Electrical System ....................................................4-1
Safe Operating Practices ....................................... 3-1
Engine Air Filter ......................................................4-5
Safe Operation ....................................................... 2-1
Engine Starting ........................................................3-3
Safe Servicing Practices ........................................ 4-1
Fuel and Evaporative Emissions Control System 4-2
Safety and Instructions Decals ............................. 2-6
Fuel Evaporation System Filter ..............................4-5
Safety Start Interlock System ................................ 3-2
Fuel Handling Precautions .....................................2-6
Seat Adjustment ..................................................... 4-9
Fuel Shut-off Valve ..........................................4-4, 4-5
Service Introduction ............................................... 4-1
General Engine Maintenance .................................4-7
Service Precautions ............................................... 2-4
General Mower Preparation for Storage ...............6-1
Slope Guide .......................................................... 2-11
Hydraulic System ....................................................4-2
Slope Operation ..................................................... 2-3
Lubrication ...............................................................4-1
Steering Control Lever Adjustment ....................... 4-9
Maintenance Locator Chart ..................................4-12
Stopping the Engine ............................................... 3-3
Maintenance Schedule .........................................4-10
System Fuses ......................................................... 4-1
Model and Serial Number .......................................1-1
Tires ........................................................................ 4-1
Moving Mower with Stalled Engine ........................3-4
To the New Owner ................................................. 1-1
Mower Blade ............................................................4-7
Torque Values ........................................................ 4-1
Mower Blade Maintenance .....................................4-7
Using a Ramp ......................................................... 2-3
Mower Blade Maintenance Precautions ................2-5
Using this Manual ................................................... 1-1
Mower Blade Replacement ....................................4-9
Warranty Registration ............................................ 1-1
606278
i-1
REV A
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